Facial interface assemblies for head-mounted displays and related systems and methods

ABSTRACT

The disclosed flexible facial interface assemblies for head-mounted display systems may include a rigid support frame element and a flexible facial interface frame element. The rigid support frame element may be shaped and configured to physically support a display of a head-mounted display system in front of a user&#39;s eyes when the facial interface assembly is worn by the user. The flexible facial interface frame element may be configured to flex to conform to the user&#39;s facial features when the facial interface assembly is worn by the user. An outer periphery of the flexible facial interface frame element may be independently movable relative to an outer periphery of the rigid support frame element. Various other systems and methods are also disclosed.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.16/213,544, filed 7 Dec. 2018, the disclosure of which is incorporated,in its entirety, by this reference.

BACKGROUND

Head-mounted display systems include a display element positioneddirectly in front of a user's eyes. Artificial reality (“AR”) systems(e.g., virtual reality, augmented reality, mixed reality, or hybridreality systems) often employ head-mounted displays to present images ofvirtual objects or scenes to the user. The virtual objects or scenes maybe part of an entirely virtual environment viewed by the user or mayoverlay views of a real-world environment surrounding the user.

When worn by the user, head-mounted displays are conventionallysupported on the user's head in a variety of ways. For example, ahalo-type head-mounted display may include a head strap that extendsfrom the user's forehead and wraps circumferentially around the user'shead. A harness-type head-mounted display may include one or more strapsor supports that extend over a top of the user's head for additionalsupport.

At least a portion of the weight of the displays and other elements ofthe head-mounted displays is held in front of the user's face. Thisweight may cause discomfort on the user's head, face, and noseparticularly after elongated periods of use. Thus, foam or otherconformable features are included on some head-mounted displays in anattempt to improve user comfort. However, different users have faces andheads with features in a wide variety of sizes and shapes, which makesit difficult to achieve user comfort for a range of users. Additionally,the displays and other elements are conventionally rigid andnon-conformable to the user's facial features.

SUMMARY

As will be described in greater detail below, the present disclosuredescribes facial interface assemblies, systems, and related methods,such as for head-mounted display systems, that may include a rigidsupport frame element to physically support a display and a flexiblefacial interface frame element to conform to the user's facial features.

In some embodiments, the present disclosure includes facial interfaceassemblies for a head-mounted display system. Such facial interfaceassemblies may include a rigid support frame element dimensioned tophysically support a display of a head-mounted display system in frontof a user's eyes when the facial interface assembly is worn by the user.The facial interface assemblies may also include a flexible facialinterface element configured to flex to conform to the user's facialfeatures when the facial interface assembly is worn by the user. Anouter periphery of the flexible facial interface frame element may beindependently movable relative to an outer periphery of the rigidsupport frame element.

In some examples, the facial interface assemblies may also include anextensible material disposed between the rigid support frame element andthe flexible facial interface frame element. The extensible material maybe configured to extend upon flexing of the flexible facial interfaceframe element away from the rigid support frame element and to retractupon flexing of the flexible facial interface frame element toward therigid support frame element. The extensible material may include aflexible fabric material, such as at least one of a woven fabricmaterial, a non-woven fabric material, a fabric material that is atleast partially transmissive to visible light, or a fabric material thatis opaque to visible light. The extensible material may include aflexible foam material, such as at least one of a closed cell foammaterial or an open cell foam material.

In additional examples, the rigid support frame element may be coupledto the flexible facial interface frame element with at least one centralsupport element. The at least one central support element may include anupper central support element coupling an upper portion of the rigidsupport frame element to an upper portion of the flexible facialinterface frame element. The upper central support element may bepositioned to be over the user's nose when the facial interface assemblyis worn by the user. The at least one central support element may alsoinclude at least one lower central support element coupling a lowerportion of the rigid support frame element to a lower portion of theflexible facial interface frame element. The at least one lower centralsupport element may include a single lower central support elementpositioned to be over the user's nose when the facial interface assemblyis worn by the user. In some examples, the at least one lower centralsupport element may include a first lower central support element to bepositioned under the user's first eye and a second lower central supportelement positioned to be over the user's second eye when the facialinterface assembly is worn by the user. The flexible facial interfaceframe element may include a nasal bridge portion that is configured toflex inward or outward to accommodate a shape of the user's nasal bridgewhen the facial interface assembly is worn by the user.

In further examples, the rigid support frame element and the flexiblefacial interface frame element may include a same material. The rigidsupport frame element and the flexible facial interface frame elementmay be parts of a unitary, integral frame body. A head strap may extendfrom the outer periphery of the flexible facial interface frame element.The head strap may include a same material as the flexible facialinterface frame element. The flexible facial interface frame element mayinclude a flexible flange that includes slits to increase a flexibilityof the flexible facial interface frame element.

In some embodiments, the present disclosure may include head-mounteddisplay systems. Such head-mounted display systems may include a displayconfigured to display images to a user's eyes when the head-mounteddisplay system is worn by the user, and a facial interface assembly. Thefacial interface assembly may include a rigid support frame element thatmay be configured to physically support the display in front of theuser's eyes when the facial interface assembly is worn by the user. Thefacial interface assembly may also include a flexible facial interfaceframe element that is configured to flex to conform to the user's facialfeatures when the facial interface assembly is worn by the user. Anouter periphery of the flexible facial interface frame element may beindependently movable relative to an outer periphery of the rigidsupport frame element.

In some examples, the display may be removable and replaceable relativeto the facial interface assembly. The facial interface assembly may alsoinclude an extensible material disposed between the rigid support frameelement and the flexible facial interface frame element and configuredto extend upon flexing of the flexible facial interface frame elementaway from the rigid support frame element.

In some embodiments, the present disclosure includes methods of forminga facial interface assembly for a head-mounted display system. Inaccordance with such methods, a rigid support frame element may becoupled to a flexible facial interface frame element. The rigid supportframe element may be configured to physically support a display of ahead-mounted display system. The flexible facial interface frame elementmay be configured to form to a user's facial features when the facialinterface assembly is worn by the user. an outer periphery of theflexible facial interface frame element is independently movablerelative to an outer periphery of the rigid support frame element. Anextensible material may be disposed between the rigid support frameelement and the flexible facial interface frame element. The extensiblematerial may be configured to extend upon flexing of the flexible facialinterface frame element away from the rigid support frame element and toretract upon flexing of the flexible facial interface frame elementtoward the rigid support frame element.

Features from any of the embodiments described herein may be used incombination with one another in accordance with the general principlesdescribed herein. These and other embodiments, features, and advantageswill be more fully understood upon reading the following detaileddescription in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate a number of example embodiments andare a part of the specification. Together with the followingdescription, these drawings demonstrate and explain various principlesof the instant disclosure.

FIG. 1 is a top front perspective view of a head-mounted display system,according to at least one embodiment of the present disclosure.

FIG. 2 is a bottom back perspective view of the head-mounted displaysystem of FIG. 1 .

FIG. 3 is a perspective view of the head-mounted display system of FIGS.1 and 2 in a partially disassembled state, according to at least oneembodiment of the present disclosure.

FIG. 4 is a perspective view of a frame body of a facial interfaceassembly as worn by a user, according to at least one embodiment of thepresent disclosure.

FIG. 5A is a perspective view of a facial interface assembly as worn bya user, according to at least one embodiment of the present disclosure.

FIG. 5B is a perspective view of the facial interface assembly of FIG.5A after flexing to conform to the user's facial features.

FIG. 6 is a perspective view of a facial interface assembly, accordingto at least one embodiment of the present disclosure.

FIG. 7 is a perspective view of a facial interface assembly, accordingto at least one embodiment of the present disclosure.

FIG. 8 is a back perspective view of a facial interface assembly,according to at least one embodiment of the present disclosure.

FIG. 9 is a top perspective view of the facial interface assembly ofFIG. 8 , shown with a flexible facial interface frame element thereof ina flexed position, according to at least one embodiment of the presentdisclosure.

FIG. 10 is a flow diagram illustrating a method of forming a facialinterface assembly, according to at least one embodiment of the presentdisclosure.

Throughout the drawings, identical reference characters and descriptionsindicate similar, but not necessarily identical, elements. While theexample embodiments described herein are susceptible to variousmodifications and alternative forms, specific embodiments have beenshown by way of example in the drawings and will be described in detailherein. However, the example embodiments described herein are notintended to be limited to the particular forms disclosed. Rather, theinstant disclosure covers all modifications, equivalents, andalternatives falling within the scope of the appended claims.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The present disclosure is generally directed to facial interfaceassemblies and related systems and methods, such as for head-mounteddisplays (e.g., artificial reality displays). As will be explained ingreater detail below, embodiments of the instant disclosure may relateto facial interface assemblies that include a rigid support frameelement and a flexible facial interface frame element. The flexiblefacial interface frame element may include an outer periphery that isindependently movable relative to an outer periphery of the rigidsupport frame element. In some examples, an extensible material may bedisposed between the flexible facial interface frame element and therigid support frame element. Such facial interface assemblies may enablea comfortable and adaptable fit for a variety of different face shapesand sizes.

The following will provide, with reference to FIGS. 1-9 , detaileddescriptions of various embodiments of facial interface assemblies forhead-mounted display systems. Detailed descriptions of example methodsof forming facial interface assemblies are provided with reference toFIG. 10 .

FIG. 1 is a top front perspective view of a head-mounted display (“HMD”)system 100. FIG. 2 is a bottom back perspective view of the HMD system100. FIG. 3 is a perspective view of the HMD system 100 in a partiallydisassembled state. Referring to FIGS. 1-3 , the HMD system 100 mayinclude a display 102, a facial interface assembly 104 for supportingthe display 102 and for resting the HMD system 100 against a user'sface, and a head strap 106 for securing the HMD system 100 on the user'shead.

The display 102 may include an electronic display for an artificialreality (e.g., virtual reality, augmented reality, mixed reality, hybridreality, etc.) system, for example. The display 102 may include one ormore display elements (e.g., LCD display elements, image combiners, hotmirrors, LED displays, OLED displays, etc.), a graphics processing unitfor rendering an image on the display element, one or more image sensors108 (e.g., cameras), one or more optical lenses 110, an eye-trackingelement, a GPS sensor, one or more motion sensors (e.g., accelerometers,proximity sensors, light sources (e.g., infrared light sources), a powersource, a wireless or wired communication component, etc. The powersource and/or wired communication component, if present, may include anelectrical cable 112, which may extend from the display 102 to acomputer, controller, battery pack, electrical outlet, mobile device,etc.

In some embodiments, the display 102 may be removable and replaceablerelative to the facial interface assembly 104, as shown in FIG. 3 . Forexample, the facial interface assembly 104 may be configured tointerchangeably support different displays 102, or to remove and replacethe display 102 for cleaning the display 102 and/or the facial interfaceassembly 104, for electrically charging the display 102, or for othermaintenance to the display 102.

The facial interface assembly 104 may include a rigid support frameelement 114 that is shaped and configured to physically support thedisplay 102 in front of a user's eyes when the facial interface assembly104 is worn by the user. Thus, the shape of the rigid support frameelement 114 may be complementary to a shape of the display 102. Therigid support frame element 114 may include one or more displayengagement elements 116 (shown in FIG. 3 ), such as magnets, notches,bumps, latches, clips, etc. for removably coupling the display 102 tothe rigid support frame element 114. In some examples, an electricalconnector 117 (FIG. 3 ) may be disposed on the rigid support frameelement 114, such as to connect the display 102 to the electrical cable112. Corresponding frame engagement elements 118 and/or a correspondingelectrical connector may be included in the display 102. In additionalembodiments, the display 102 may be removably coupled to the rigidsupport frame element 114 without use of the engagement elements 116,118. For example, the display 102 may snugly fit within the rigidsupport frame element 114 and may be held in place by friction.

The facial interface assembly 104 may also include a flexible facialinterface frame element 120 that is configured to flex to conform to theuser's facial features when the HMD system 100 is worn by the user. Afacial interface padding 122 (shown in FIG. 2 ) may be disposed on aninner (i.e., toward the user's face when worn) surface of the flexiblefacial interface frame element 120 to provide a comfortable fit againstthe user's face. The facial interface padding 122 may include, forexample, a closed cell foam or an open cell foam, which may or may notbe covered by a fabric material. A frame body 123 of the facialinterface assembly 104 may include both the rigid support frame element114 and the flexible facial interface frame element 120.

At least a portion (e.g., an outer periphery 124, a nasal bridge portion126, etc.) of the flexible facial interface frame element 120 may beflexible in a forward and backward direction A (relative to a userwearing the HMD system 100) to flex and conform to the user's facialsize and shape when the HMD system 100 is worn by the user. In someexamples, the terms “flexible” and “rigid” may be used in a relativesense. For example, the flexible facial interface frame element 120 maybe relatively more flexible than the rigid support frame element 114 inthe forward and backward direction A, even though both of these elementsmay exhibit some level of flexibility. For example, both of the flexiblefacial interface frame element 120 and the rigid support frame element114 may be formed of the same material. By way of example and notlimitation, the flexible facial interface frame element 120 and therigid support frame element 114 may be formed of a polymer material, ametal material, a fiber-matrix composite material, or a combinationthereof. In one non-limiting example, the frame body 123, including theflexible facial interface frame element 120 and the rigid support frameelement 114, may be formed of a thermoplastic polymer material, such asnylon.

The relative flexibility of the flexible facial interface frame element120 may be accomplished by the material properties and/or configurationof the material forming the flexible facial interface frame element 120.For example, a thickness of the flexible facial interface frame element120 in the forward and backward direction A (relative to a user wearingthe HMD system 100) may be sufficiently small to enable flexing in theforward and backward direction A with an application of a relativelysmall force (e.g., a force applied by the head strap 106 to comfortablyhold the HMD system 100 on the user's head). Due to its flexibility inat least the forward and backward direction A, the flexible facialinterface frame element 120 may be customizable and adaptable to avariety of different face shapes, features, and/or sizes, as will beexplained further below with reference to FIGS. 5A and 5B. In additionalexamples, the material of the flexible facial interface frame element120 may be selected for its flexibility. For example, the flexiblefacial interface frame element 120 may be or include a foam material,which may or may not be covered with a flexible coating, such as asilicone or rubber coating.

The relative rigidity of the rigid support frame element 114 may beaccomplished by the material properties and/or configuration of thematerial forming the rigid support frame element 114. For example, therigid support frame element 114 may be or include a lip 128 having awidth in a generally forward and backward direction A (relative to auser wearing the HMD system 100) that is sufficient to reduceflexibility of at least a portion (e.g., an outer periphery 130) of therigid support frame element 114 in the forward and backward direction A.In addition, coupling the display 102 to the rigid support frame element114 may further inhibit flexing of the rigid support frame element 114in the forward and backward direction A.

The rigid support frame element 114 may be coupled to (e.g., attachedto, adhered to, integrally formed with, or fastened to, etc.) andphysically supported by the flexible facial interface frame element 120.At least one central support element 132 may couple the rigid supportframe element 114 to the flexible facial interface frame element 120.The at least one central support element 132 may include, for example,an upper central support element 134 extending between and coupling anupper portion of the rigid support frame element 114 to an upper portionof the flexible facial interface frame element 120. The upper centralsupport element 134 may be positioned to be over the user's nose whenthe HMD system 100 is worn by the user. The upper central supportelement 134 may be sized and configured to physically support at least aportion of the rigid support frame element 114 and the display 102. Theupper central support element 134 may also provide a standoff betweenthe rigid support frame element 114 and the flexible facial interfaceframe element 120, such as to provide space for components of thedisplay 102, to provide relief for the user's nose, etc.

The at least one central support element 132 may also include at leastone lower central support element 136 coupling a lower portion of therigid support frame element 114 to a lower portion of the flexiblefacial interface frame element 120. For example, the at least one lowercentral support element 136 may include a first lower central supportelement 136A positioned to be under the user's first eye and a secondlower central support element 136B positioned to be under the user'ssecond eye when the HMD system 100 is worn by the user.

The frame body 123 may include and/or be defined by the rigid supportframe element 114, the flexible facial interface frame element 120, andthe at least one central support element 132 (e.g., the upper centralsupport element 134 and the first and second lower central supportelements 136A, 136B). In some embodiments, these components of the framebody 123 may be parts of an integral, unitary frame body 123. Forexample, the rigid support frame element 114, the flexible facialinterface frame element 120, and the at least one central supportelement 132 may be formed by a molding and/or three-dimensional printingprocess. In additional embodiments, the components of the frame body 123may be formed separately from each other and secured together, such asvia fasteners, welds, and/or adhesives.

In some examples, the at least one central support element 132 may havea variable and controllable length. For example, a user may be able tomodify a distance between the user's eyes and the display 102 or anangle of the display 102 relative to the user's eyes by turning a screwor actuating a linear actuator to modify a length of the at least onecentral support element 132 (e.g., by modifying a length of one or moreof the upper central support element 134, the first lower centralsupport element 136A, or the second lower central support element 136B).

The frame body 123 of the facial interface assembly 104 may lack anysupport element between the outer periphery 124 of the flexible facialinterface frame element 120 and the outer periphery 130 of the rigidsupport frame element 114. Thus, the outer periphery 124 of the flexiblefacial interface frame element 120 may be independently movable (e.g.,in the forward and backward direction A relative to the user wearing theHMD system 100) relative to the outer periphery 130 of the rigid supportframe element 114. Therefore, flexing of at least the outer periphery124 of the flexible facial interface frame element 120 to conform to theuser's facial features upon wearing the HMD system 100 may besubstantially unimpeded by the rigid support frame element 114 and thedisplay 102.

In some examples, the term “substantially” in reference to a givenparameter, property, or condition may refer to a degree that one skilledin the art would understand that the given parameter, property, orcondition is met with a small degree of variance, such as withinacceptable manufacturing tolerances. For example, a parameter that issubstantially met may be at least about 90% met, at least about 95% met,or at least about 99% met.

In some embodiments, the facial interface assembly 104 of the HMD system100 may include an extensible material 138 disposed between the rigidsupport frame element 114 and the flexible facial interface frameelement 120. The extensible material 138 may be configured to extendupon flexing of the flexible facial interface frame element 120 awayfrom the rigid support frame element 114 and to retract upon flexing ofthe flexible facial interface frame element 120 toward the rigid supportframe element 114. For example, the extensible material 138 may be orinclude a flexible fabric material, such as one or more of a wovenfabric material, a non-woven fabric material, a fabric material that isat least partially transmissive to visible light, or a fabric materialthat is opaque to visible light. In additional examples, the extensiblematerial 138 may be or include a flexible foam material, such as atleast one of a closed cell foam material or an open cell foam material.The extensible material 138 may exhibit material properties thatfacilitate extension and/or retraction without substantially inhibitingflexing of the flexible facial interface frame element 120 away from therigid support frame element 114 to conform to the user's facialfeatures.

The extensible material 138 may, in some embodiments, be configured toblock visible light from entering into the HMD system 100 when worn bythe user. The extensible material 138 may also be configured to inhibitpassage of debris (e.g., dust) into an interior of the HMD system 100when worn. In some embodiments, the extensible material 138 may be orinclude a breathable fabric material to enable cooling of the interiorof the HMD system 100 and/or to inhibit condensation of perspirationwithin the interior of the HMD system 100.

FIG. 4 is a perspective view of a frame body 423 of a facial interfaceassembly 404 as worn by a user, according to at least one embodiment ofthe present disclosure. The user's nose 450 is shown in FIG. 4 toillustrate placement of the facial interface assembly 400 on the user'sface. The facial interface assembly 404 may be the same or similar tothe facial interface assembly 104 described above with reference toFIGS. 1-3 . For example, the facial interface assembly 504 may include arigid support frame element 414 and a flexible facial interface frameelement 420. A facial interface padding 422 may be disposed on an inner(e.g., toward the user's face when worn) surface of the flexible facialinterface frame element 420. An outer periphery 424 of the flexiblefacial interface frame element 420 may be decoupled (e.g., independentlymovable, lacking a support element) from an outer periphery 430 of therigid support frame element 414. A nasal bridge portion 426 of theflexible facial interface frame element 420 may be positioned to be overa nasal bridge of the user's nose 450 when worn. As discussed above, therigid support frame element 414 may be or include a lip 428 with asufficient width in a forward and backward direction B (relative to theuser) to inhibit flexing of the rigid support frame element 414 in theforward and backward direction B. An upper central support element 434may couple upper portions of the rigid support frame element 414 andflexible facial interface frame element 420 to each other. First andsecond lower central support elements 436A, 436B may couple lowerportions of the rigid support frame element 414 and flexible facialinterface frame element 420 to each other.

As shown in FIG. 4 , the nasal bridge portion 426 of the flexible facialinterface frame element 420 may be configured to flex to conform to theuser's nose 450. Different users may have different nose shapes andsizes. The flexing of the nasal bridge portion 426 may accommodate suchdifferent nose shapes and sizes for a comfortable fit on a variety ofdifferent users. For example, the nasal bridge portion 426 may beconfigured to flex forward and backward to accommodate user noses 450with respectively protruding or flat nasal bridges, as indicated by thearrow 452. The nasal bridge portion 426 of the flexible facial interfaceframe element 420 may, in some embodiments, also be configured to flexinward and outward to accommodate respectively narrow or wide user noses450, as indicated by the arrows 454. Such movement of the nasal bridgeportion 426 may be substantially independent from the rigid supportframe element 414. Thus, movement of the nasal bridge portion 426 toconform to a user's facial features (e.g., the user's nose 450) may notresult in substantial movement of the rigid support frame element 414.

FIG. 5A is a perspective view of a facial interface assembly 504 as wornby a user, according to at least one embodiment of the presentdisclosure. FIG. 5B is a perspective view of the facial interfaceassembly 504 after flexing to conform to a user's head 160. The facialinterface assembly 504 may be the same or similar to the facialinterface assembly 104 described above with reference to FIGS. 1-3 . Forexample, the facial interface assembly 504 may include a rigid supportframe element 514 and a flexible facial interface frame element 520. Ahead strap 506 may extend backward (relative to the user when the facialinterface assembly 504 is worn by the user) from the facial interfaceassembly 504A to secure the facial interface assembly 504 on the user'shead 560. A facial interface padding 522 may be disposed on an inner(e.g., toward the user's head 560 when worn) surface of the flexiblefacial interface frame element 520. The flexible facial interface frameelement 520 may include a nasal bridge portion 526 positioned over theuser's nose. The rigid support frame element 514 and the flexible facialinterface frame element 520 may be parts of a frame body 523.

As shown in FIGS. 5A and 5B, an outer periphery 524 of the flexiblefacial interface frame element 520 may be decoupled (e.g., independentlymovable, lacking a support element) from an outer periphery 530 of therigid support frame element 514. As discussed above, the rigid supportframe element 514 may be or include a lip 528 with a sufficient width ina forward and backward direction (relative to the user) to inhibitflexing of the rigid support frame element 514 in the forward andbackward direction. An upper central support element 534 may coupleupper portions of the rigid support frame element 514 and flexiblefacial interface frame element 520 to each other. First and second lowercentral support elements 536A, 536B may couple lower portions of therigid support frame element 514 and flexible facial interface frameelement 520 to each other. However, the facial interface assembly 504may lack any support elements between the outer periphery 524 of theflexible facial interface frame element 520 and outer periphery 530 ofthe of the rigid support frame element 514. Thus, when the facialinterface assembly 504 is placed on the user's head 560 and the headstrap 506 is tightened, the flexible facial interface frame element 520may flex backward to conform to the user's head 560, as indicated inFIG. 5A by arrow 562. The facial interface assembly 504 may beconformable to comfortably fit on a variety of different user heads 560that have different shapes and sizes. The flexibility of the outerperiphery 524 of the flexible facial interface frame element 520 may besubstantially unimpeded by the rigid support frame element 514.

FIG. 6 is a perspective view of a facial interface assembly 604 for anHMD system according to at least one additional embodiment. The facialinterface assembly 604 may be similar in some respects to the facialinterface assembly 104 discussed above. For example, the facialinterface assembly 604 may include a rigid support frame element 614 forsupporting a display and a flexible facial interface frame element 620configured to flex to conform to a user's facial features when thefacial interface assembly 604 is worn by the user. An outer periphery624 of the flexible facial interface frame element 620 may beindependently movable (e.g., in a forward and backward direction Crelative to the user) relative to an outer periphery 630 of the rigidsupport frame element 614. The rigid support frame element 614 mayinclude a lip 628 having a width in the forward and backward direction Cthat is sufficient to inhibit flexing of the rigid support frame element614 in the forward and backward direction C.

As shown in FIG. 6 , in some embodiments, the facial interface assembly604 may also include a head strap 606 that may be an integral portion ofthe flexible facial interface frame element 620, rather than a separatepiece that is coupled to the facial interface assembly 604. The rigidsupport frame element 614 may include a flange 670 extending outwardfrom a rear portion of the lip 628. The flange 670 may, for example,provide material for connecting other components of the facial interfaceassembly 604 or a corresponding HMD system. The flange 670 may alsoincrease a rigidity of the rigid support frame element 614.

The facial interface assembly 604 may include a single upper centralsupport element 634 coupled to and extending between an upper portion ofthe rigid support frame element 614 and an upper portion of the flexiblefacial interface frame element 620. The upper central support element634 may be positioned to be over (e.g., above) the user's nose when thefacial interface assembly is worn by the user. The facial interfaceassembly 604 may also include a single lower support element 636coupling the rigid support frame element 614 to the flexible facialinterface frame element 620. The lower support element 636 may bepositioned to be over (e.g., on) the user's nose when the facialinterface assembly 604 is worn by the user. In some examples, the lowersupport element 636 may be an extension (e.g., protrusion) of theflexible facial interface frame element 620, and the lower supportelement 636 may be coupled (e.g., attached, adhered, welded, integrallyformed, fastened, etc.) to the rigid support frame element 614. Inadditional examples, the lower support element 636 may be a separateelement positioned between the flexible facial interface frame element620 and the rigid support frame element 614. As shown in FIG. 6 , theouter periphery 624 of the flexible facial interface frame element 620may be independently movable relative to the outer periphery 630 of therigid support frame element 614. For example, the facial interfaceassembly 604 may lack a support element positioned between these outerperipheries 624, 630.

The rigid support frame element 614, flexible facial interface frameelement 620, upper central support element 634, and lower supportelement 636 may be parts of a frame body 623. In some examples, the headstrap 606 may also be a part of the frame body 623. In some embodiments,the components of the frame body 623 may be integrally formed (e.g., viamolding, three-dimensional printing, etc.) to define an integral,unitary frame body 623.

FIG. 7 is a perspective view of the facial interface assembly 604 withan extensible material 638 positioned between the rigid support frameelement 614 and the flexible facial interface frame element 620,according to at least one embodiment of the present disclosure. By wayof example and not limitation, the extensible material 638 may be aflexible foam material, such as an open cell foam material or a closedcell foam material. In one example, the extensible material 638 may be apolyurethane foam material. The extensible material 638 may be formedby, for example, positioning the frame body 623 in a mold cavity andovermolding the frame body 623 with a foam material. Alternatively, theextensible material 638 may be pre-formed and coupled (e.g., adhered,bolted, clipped, engaged, etc.) to the frame body 623.

FIG. 8 is a back perspective view of a facial interface assembly 804 foran HMD system according to additional embodiments. FIG. 9 is a topperspective view of the facial interface assembly 804, showing aflexible facial interface frame element 820 thereof in a flexedposition. A frame body 823 of the facial interface assembly 804 mayinclude the flexible facial interface frame element 820 and a rigidsupport frame element 814 for supporting a display 802. The flexiblefacial interface frame element 820 and the rigid support frame element814 may be coupled to each other with an upper central support element834 and a lower central support element 836. For example, the centralsupport elements 834, 836 may include screws or other fasteners.

The flexible facial interface frame element 820 may include a flexibleflange 880 extending forward (relative to a user wearing the facialinterface assembly 804) toward the rigid support frame element 814. Theflexible flange 880 may be formed with slits 882 to increase aflexibility of the flexible flange 880 and of the flexible facialinterface frame element 820, as shown in FIGS. 8 and 9 . Additionally,the slits 882 may improve a breathability of the facial interfaceassembly 804. The flexible flange 880 may be present to provide astandoff between the flexible facial interface frame element 820 and therigid support frame element 814 and to block at least some externalvisible light from reaching the user's eyes.

The flexible facial interface frame element 820 may also include headstrap attachment features 884 (FIG. 9 ) at or near an outer periphery824 thereof. The outer periphery 824 of the flexible facial interfaceframe element 820 may be independently movable in the forward andbackward direction (relative to a user wearing the facial interfaceassembly 804) relative to an outer periphery 830 of the rigid supportframe element 814. For example, as illustrated in FIG. 9 , tightening ahead strap may pull the head strap attachment features 884 and the outerperiphery 824 of the flexible facial interface frame element 820 in adirection away from the rigid support frame element 814, as shown byarrows 886. Upon flexing of the flexible facial interface frame element820 backwards, the slits 882 may widen to allow the flexible flange 880to stretch and the flexible facial interface frame element 820 toconform to the user's facial features (e.g., head). In some embodiments,an extensible material (e.g., an extensible fabric and/or an extensiblefoam) may be positioned over an exterior of the flexible flange 880 andbetween the rigid support frame element 814 and the flexible facialinterface frame element 820, as explained above.

FIG. 10 is a flow diagram illustrating a method 1000 of forming a facialinterface assembly, according to at least one embodiment of the presentdisclosure. At operation 1010, a rigid support frame element may becoupled to a flexible facial interface frame element. Operation 1010 maybe performed in a variety of different ways. For example, coupling therigid support frame element to the flexible facial interface frameelement may include forming these frame elements as an integral, unitaryframe body, such as by molding or three-dimensional printing.Alternatively, the rigid support frame element and the flexible facialinterface frame element may be formed separately and coupled to eachother. In some embodiments, at least one central support element (e.g.,an upper central support element and at least one lower central supportelement) may be used to couple the rigid support frame element and theflexible facial interface frame element to each other, as describedabove. The coupling of these two frame elements to each other mayinclude coupling a central portion thereof to each other, while leavingouter peripheries of the rigid support frame element and of the flexiblefacial interface frame element decoupled (e.g., not connected by anyrigid or otherwise non-extensible support element) from each other.Decoupling the outer peripheries may enable substantially independentmovement of the outer periphery of the flexible facial interface frameelement relative to the rigid support frame element in the forward andbackward direction (relative to a user wearing the facial interfaceassembly), as described above.

At operation 1020, an extensible material may be disposed between therigid support frame element and the flexible facial interface frameelement. The extensible material may be configured to extend uponflexing of the flexible facial interface frame element away from therigid support frame element and to retract upon flexing of the flexiblefacial interface frame element toward the rigid support frame element,such as to conform to facial features of a user. Operation 820 may beperformed in a variety of different ways. For example, a flexible fabric(e.g., a woven fabric material, a non-woven fabric material, a fabricmaterial that is at least partially transmissive to visible light, afabric material that is opaque to visible light, etc.) may be disposedbetween the rigid support frame element and the flexible facialinterface frame element. Additionally or alternatively, a flexible foammaterial (e.g., a closed cell foam material, an open cell foam material,a polyurethane foam material, etc.) may be disposed between the rigidsupport frame element and the flexible facial interface frame element.

In some examples, the method 1000 of forming the facial interfaceassembly may include additional operations, such as coupling a headstrap to the flexible facial interface frame element, disposing a facialinterface padding (e.g., foam) material on an inner surface of theflexible facial interface frame element, removably coupling a display(e.g., an artificial reality display) to the rigid support frameelement, coupling an electrical cable to the rigid support frameelement, etc.

Accordingly, disclosed are facial interface assemblies and relatedsystems and methods that may be useful for, by way of example and notlimitation, HMD systems (e.g., artificial reality systems). The facialinterface assemblies may include a rigid support frame element forsupporting a display and a flexible facial interface assembly. At leastouter peripheries of the flexible facial interface assemblies may beindependently movable in forward and backward directions relative to therigid support frame element, resulting in a versatile, adaptable, andcomfortable fit on a user's face.

Embodiments of the instant disclosure may include or be implemented inconjunction with an artificial reality system. Artificial reality is aform of reality that has been adjusted in some manner beforepresentation to a user, which may include, e.g., a virtual reality (VR),an augmented reality (AR), a mixed reality (MR), a hybrid reality, orsome combination and/or derivatives thereof. Artificial reality contentmay include completely generated content or generated content combinedwith captured (e.g., real-world) content. The artificial reality contentmay include video, audio, haptic feedback, or some combination thereof,any of which may be presented in a single channel or in multiplechannels (such as stereo video that produces a three-dimensional effectto the viewer). Additionally, in some embodiments, artificial realitymay also be associated with applications, products, accessories,services, or some combination thereof, that are used to, e.g., createcontent in an artificial reality and/or are otherwise used in (e.g.,perform activities in) an artificial reality. The artificial realitysystem that provides the artificial reality content may be implementedon various platforms, including a head-mounted display (HMD) connectedto a host computer system, a standalone HMD, a mobile device orcomputing system, or any other hardware platform capable of providingartificial reality content to one or more viewers.

The process parameters and sequence of the steps described and/orillustrated herein are given by way of example only and can be varied asdesired. For example, while the steps illustrated and/or describedherein may be shown or discussed in a particular order, these steps donot necessarily need to be performed in the order illustrated ordiscussed. The various example methods described and/or illustratedherein may also omit one or more of the steps described or illustratedherein or include additional steps in addition to those disclosed.

The preceding description has been provided to enable others skilled inthe art to best utilize various aspects of the example embodimentsdisclosed herein. This example description is not intended to beexhaustive or to be limited to any precise form disclosed. Manymodifications and variations are possible without departing from thespirit and scope of the instant disclosure. The embodiments disclosedherein should be considered in all respects illustrative and notrestrictive. Reference should be made to the appended claims and theirequivalents in determining the scope of the instant disclosure.

Unless otherwise noted, the terms “connected to” and “coupled to” (andtheir derivatives), as used in the specification and claims, are to beconstrued as permitting both direct and indirect (i.e., via otherelements or components) connection. In addition, the terms “a” or “an,”as used in the specification and claims, are to be construed as meaning“at least one of.” Finally, for ease of use, the terms “including” and“having” (and their derivatives), as used in the specification andclaims, are interchangeable with and have the same meaning as the word“comprising.”

What is claimed is:
 1. A facial interface assembly for a head-mounteddisplay system, comprising: a rigid support frame element dimensioned tophysically support a display of a head-mounted display system; and aflexible facial interface frame element configured to rest against auser's face laterally outside of the user's eyes and to flex to conformto the user's facial features when the facial interface assembly is wornby the user, the flexible facial interface frame element comprising atleast one central support element that structurally supports theflexible facial interface frame element in a laterally central region ofthe flexible facial interface frame element, wherein a laterally outerperipheral region of the flexible facial interface frame elementlaterally outside of the at least one central support element lacks anysupport element between the laterally outer peripheral region of theflexible facial interface frame element and a laterally outer peripheralregion of the rigid support frame element such that the laterally outerperipheral region of the flexible facial interface frame element isindependently movable relative to the rigid support frame element. 2.The facial interface assembly of claim 1, further comprising anextensible material disposed between the rigid support frame element andthe flexible facial interface frame element and configured to extendupon flexing of the flexible facial interface frame element away fromthe rigid support frame element and to retract upon flexing of theflexible facial interface frame element toward the rigid support frameelement.
 3. The facial interface assembly of claim 2, wherein theextensible material comprises a flexible fabric material.
 4. The facialinterface assembly of claim 3, wherein the flexible fabric materialcomprises at least one of: a woven fabric material; a non-woven fabricmaterial; a fabric material that is at least partially transmissive tovisible light; or a fabric material that is opaque to visible light. 5.The facial interface assembly of claim 2, wherein the extensiblematerial comprises a flexible foam material.
 6. The facial interfaceassembly of claim 5, wherein the flexible foam material comprises atleast one of: a closed cell foam material; or an open cell foammaterial.
 7. The facial interface assembly of claim 1, wherein the atleast one central support element comprises multiple central supportelements.
 8. The facial interface assembly of claim 1, wherein the atleast one central support element comprises an upper central supportelement coupling an upper portion of the rigid support frame element toan upper portion of the flexible facial interface frame element, whereinthe upper central support element is positioned to be over the user'snose when the facial interface assembly is worn by the user.
 9. Thefacial interface assembly of claim 8, wherein the at least one centralsupport element further comprises at least one lower central supportelement coupling a lower portion of the rigid support frame element to alower portion of the flexible facial interface frame element.
 10. Thefacial interface assembly of claim 9, wherein the at least one lowercentral support element comprises a single lower central support elementpositioned to be over the user's nose when the facial interface assemblyis worn by the user.
 11. The facial interface assembly of claim 9,wherein the at least one lower central support element comprises a firstlower central support element positioned to be under the user's firsteye and a second lower central support element positioned to be underthe user's second eye when the facial interface assembly is worn by theuser.
 12. The facial interface assembly of claim 11, wherein theflexible facial interface frame element comprises a nasal bridge portionthat is configured to flex inward or outward to accommodate a shape ofthe user's nasal bridge when the facial interface assembly is worn bythe user.
 13. The facial interface assembly of claim 1, wherein therigid support frame element and the flexible facial interface frameelement comprise a same material.
 14. The facial interface assembly ofclaim 13, wherein the rigid support frame element and the flexiblefacial interface frame element are parts of a unitary, integral framebody.
 15. The facial interface assembly of claim 1, further comprising ahead strap extending from the laterally outer peripheral region of theflexible facial interface frame element, such that the laterally outerperipheral region of the flexible facial interface frame element flexesaway from the rigid support element when the head strap is tightenedaround a head of the user, wherein the head strap comprises a samematerial as the flexible facial interface frame element.
 16. The facialinterface assembly of claim 1, wherein the flexible facial interfaceframe element comprises a flexible flange that includes slits toincrease a flexibility of the flexible facial interface frame element.17. A head-mounted display system, comprising: a display configured todisplay images to a user's eyes when the head-mounted display system isworn by the user; and a facial interface assembly, comprising: a rigidsupport frame element configured to physically support the display infront of the user's eyes when the facial interface assembly is worn bythe user; a flexible facial interface frame element configured to restagainst the user's face laterally outside of the user's eyes when thehead-mounted display system is worn by the user; and at least onecentral support element that structurally supports the flexible facialinterface frame element in a laterally central region of the flexiblefacial interface frame element, wherein a laterally outer peripheralregion of the flexible facial interface frame element laterally outsideof the at least one central support element lacks any support elementbetween the laterally outer peripheral region of the flexible facialinterface frame element and the rigid support frame element such thatthe laterally outer peripheral region of the flexible facial interfaceframe element is independently movable relative to the rigid supportframe element.
 18. The head-mounted display system of claim 17, whereinthe display is removable and replaceable relative to the facialinterface assembly.
 19. The head-mounted display system of claim 17,wherein the facial interface assembly further comprises an extensiblematerial disposed between the rigid support frame element and theflexible facial interface frame element and configured to extend uponflexing of the flexible facial interface frame element away from therigid support frame element.
 20. A method of forming a facial interfaceassembly for a head-mounted display system, the method comprising:coupling a laterally central region of a flexible facial interface frameelement to a rigid support frame element with at least one centralsupport element, wherein the rigid support element is configured tophysically support a display of a head-mounted display system, theflexible facial interface frame element is configured to rest against auser's face laterally outside of the user's eyes, and a laterally outerperipheral region of the flexible facial interface frame elementlaterally outside of the at least one central support element lacks anysupport element and is structurally decoupled from and independentlymovable relative to a laterally outer peripheral region of the rigidsupport frame element; and disposing an extensible material between therigid support frame element and the flexible facial interface frameelement, wherein the extensible material is configured to extend uponflexing of the flexible facial interface frame element away from therigid support frame element and to retract upon flexing of the flexiblefacial interface frame element toward the rigid support frame element.